Remy 22SI All Replaceable Components 10539632 - Manual (Page 2)

3. If replacing the SRE bearing or brush holder assembly, remove brush holder assembly, washer and any other parts that could be
damaged by pushing the bearing out with a press.
4. Push the bearing out, with a press, from the back of frame (closed end of bearing) inward and install replacement bearing. See
graphic on page 3 for correct dimensional location of bearing in the frame.
WARNING!!! MULTIPLE STYLES OF SCREW ASSEMBLIES ARE USED, INCLUDING INSULATED AND NON-INSULATED, FOR
REGULATORS AND RECTIFIER BRIDGES. THE SCREW ASSEMBLIES MUST BE REPLACED IN THE SAME LOCATION AS
REMOVED TO AVOID GROUNDING OR OTHER UNDESIREABLE RESULTS.
5. If replacing terminal assemblies, it is advisable replace them one at a time, carefully noting parts and stack up and where leads are
connected. Torque requirements for the "R", "I" & "sense" terminal nuts are 1.7 - 2.8 Nm (15 - 20 lb in). The output (B+) terminal
torques are as follows: 1/4” is 5.7 - 6.8 Nm (50 - 60 lb in),
M6 is 6.8 - 9.0 Nm (60 - 80 lb in), 5/16” is 7.4 - 11.1 Nm (65 - 98 lb in).
All terminals are insulated from the SRE frame.
DANGER!!! If all terminals are not kept insulated from the frame when the battery is connected, they can quickly get hot enough to
burn skin and damage surrounding parts.
6. Remove brush holder assembly by first pushing brushes back, placing a pin through holes in brush holder and brushes to keep
them in place, and removing the three (3) mounting screw assemblies, noting positions of the insulated screws.
7. Install brush holder assembly, three (3) mounting screws and torque to 1.7 - 2.8 Nm (15 - 20 lb in). The two (2) insulated screws also
serve as regulator mounting screws.
8. Install a pin through holes in the SRE frame and brushes to allow for installation of the rotor. Remove pin after reassembly of the
alternator.
9. If replacing the regulator, remove the nut, loosen the "B+" terminal nut and remove the three (3) screw assemblies, carefully
noting where leads and/or straps are connected. The connections are as follows: "F-" -The terminal is connected to field coil
at brush holder with an insulated screw. "GRD" -Nothing is connected. "F+" -The "I" and diode trio straps are connected
with an insulated screw. "Sense" -The strap from the #5 rectifier bridge position is connected.
10. Install new regulator and reconnect leads and straps as removed. Install and torque the three (3) screw assemblies to 1.8 - 2.3 Nm
(16 - 20 lb in) and the nut assembly to 1.7 - 2 .8 Nm (15 - 25 lb in).
11. If replacing the diode trio or diode trio & autostart, remove nut assemblies from P1 terminal, loosen the "R" terminal strap , P2, &
P3 rectifier terminals, noting how the three (3) stator leads connect to the "P" terminals. If replacing diode trio & autostart,
continue to remove screws from #2 (insulated) and #3 rectifier positions.
12. Install the replacement diode trio or autostart, screws in #2 (insulated) and #3 rectifier positions, "R" terminal strap and stator
leads, insuring leads are all the way down. Reinstall the three (3) phase terminal nut assemblies and torque to 1.7 - 2.8 Nm
(15 - 25 lb in). Install and torque the insulated screw, that connects the "I" terminal and trio straps to the "F+" regulator
terminal, to 2.5 - 3.4 Nm (22 - 30 lb in).
Tighten the "I" terminal nut to 1.7 - 2 .8 Nm (15 - 25 lb in) and output terminal nut
according to size. See values in line 5 for correct torque. If autostart, install and torque the #2 position insulated screw and #3
position screw to 2.5 - 3.4 Nm (22 - 30 lb in).
.
13. If replacing rectifier bridge, remove the diode trio or diode trio & autostart plus the remaining screw from #4 position.
14. Install rectifier bridge assembly and replace all straps and connectors as removed. See above steps for terminations and torque
values.
COMPONENT ASSSEMBLY INSTRUCTIONS
1. Assemble the DE frame and rotor assembly with the SRE frame assembly, being sure to line up the non-threaded mounting lugs or
marks. This is best accomplished by inserting a tolerance pin in the non-threaded holes on hinge mount (J180) units or two (2)
parallel blocks with pad mount units.
2. Install the four (4) thru bolts and torque to 50% of final value. Use a staggered sequence to finish and torque thru-bolts to
10.7 - 11.9 Nm (95 - 105 lb).
3. Install external fan, pulley and pulley nut. Torque pulley nut to 95-108 Nm (70-80 lb ft).
REINSTALL THE ALTERNATOR ACCORDING TO ENGINE OR VEHICLE MANFACTURERS INSTRUCTION’S
♦ Reattach the battery (+) terminal lead to alternator battery terminal and torque nut to 9.0-13.0 Nm (80 - 120 lb in).
♦ Reconnect the negative (-) cable at the battery.
NOTICE - Only licensed Remy International, Inc. product and component parts should be used, and the use of other parts or modifications not approved
by Remy International, Inc. will void all applicable warranties. The failure to carefully follow these Installation Instructions, set forth above, will void all
applicable warranties. DELCO REMY is a registered trademark of General Motors Corporation, licensed to Remy International, Inc. Pendleton, IN 46064.
© 2012 Remy International, Inc. All rights reserved
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www.delcoremy.com